Simulation of surface generated in abrasive flow machining process

For the control of abrasive flow machining (AFM) process, it is important to understand the mechanics of generation of its surface profile. This paper describes the analysis and simulation of profile of finished surface and material removal by the interaction of abrasive grains with workpiece. The abrasive grains are randomly distributed in media depending upon their percentage concentration and mesh size. The results predicted from simulation and obtained from response surface analysis (or experiments) are compared to explain the relative importance of AFM parameters. The generated surface profile and material removal are the function of number of cycles, percentage concentration and mesh size of abrasives, reduction ratio and extrusion pressure applied.